Fire barriers for multi-dimensional architectural expansion joints

ABSTRACT

Multi-layered, multi-directional, multi-dimensional and planar fire barriers for use in flue-like spaces formed by angled intersections of architectural expansion joints comprise a plurality of fire resistant material layers. The fire barriers are shaped for use in 2-way planar L-shaped expansion joint spaces, T-shaped, cross-shaped, V-shaped, and vertical/horizontal L-shaped corner expansion joint spaces, for example. A fire barrier may comprise at least one mechanically supporting layer; at least one insulating layer, and at least one layer of intumescent material, wherein the insulating layer is disposed between the mechanical support layer and the intumescent layer and the layered barrier is protected by an underlying protective cloth. The barrier, which prohibits the travel of fire, heat, or smoke through the flue-like channels created by the expansion joints of a structure, is provided ready to install in a one-step, drop-in process using a ready to assemble, width-adjustable, installation tool provided in a kit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Continuation Application claims the benefit of U.S. applicationSer. No. 10/854,392 filed May 26, 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates generally to fire barriers and moreparticularly to one-step, drop-in installation, fire barriers formulti-dimensional, multi-directional, architectural expansion joints.

The background information discussed below is presented to betterillustrate the novelty and usefulness of the present invention. Thisbackground information is not admitted prior art. The particularversions of the invention as described below are provided, in part, asillustrative and exemplary. Thus, the described versions should not betaken as limiting. Additionally, the invention is not limited to theexamples provided.

Customarily, buildings were built with static joints. Modern buildingcodes, however, require that building design and construction now takeinto account factors that can, over time, change the physical dimensionsof a structure. These factors include extreme or repetitive changes intemperature, the force of wind impinging on the building, forces due toseismic events, settling of the subsoil, remodeling of the building, orexcavation on or near the site, among other factors. To accommodate thestress on the building caused by these factors without compromising theintegrity of the building, architects and builders may design thestructure in sub-units where the sub-units are meant to remain somesmall distances away from each other and meet at what is referred to as“expansion joints”.

Expansion joints allow differential building movement to take placewithout risking damage to the whole structure. These joints representgaps in the structure which can widen or narrow due to differentialmovement of adjacent structural units and/or can reduce the stresscaused by shear motion of adjacent structural units. Dynamic moveablejoints are often referred to in the trade as “construction joints,”“soft joints,” “dynamic voids”, “seismic joints,” and “expansionjoints.” Expansion joints or voids often occur where two wall sections,a wall and a floor, or a wall and ceiling meet, for example.

While the presence of these joints improves the integrity of thestructure as a whole, they present a major risk to the structure in theevent of a fire. The gaps at the joints provide easy pathways for flame,heat, and smoke to spread rapidly throughout the structure by utilizingwhat is known as the “chimney effect,” that is the updraft created byheated air rising up through the structural gaps. Building codes forcommercial structures generally require fire barriers capable ofpreventing flame and smoke from passing through building joints intoadjoining areas. Various fire barrier means are available and includefire retardant and/or intumescent putties, caulks, wraps, and mats.

The fire barrier products mentioned above, although suitable for staticjoints, are generally not suitable for acting as fire barriers fordynamic joints. To reduce the risk created by the chimney effect due todynamic joints, a number of attempts have been made to block the jointswith fire resistant materials. A fire barrier for a dynamic jointgenerally needs to be capable of accommodating the complex differentialmovement of the building structural units and to retain its resiliencyover an extended period of time under dynamic conditions. Further,during a fire event, the joint is likely to be subject to even greatermovement, thereby making it essential that the fire barrier retains itsintegrity to prevent the migration of heat, flame, and smoke.

Commonly available are fire resistant materials, such as fire brick,which typically may be either rigid and/or brittle, or fire barrierblankets that are constructed of refractory fibers that are flexible butcan be easily damaged.

Rigid and brittle materials have been adapted to sealing building jointswhile maintaining flexibility. This is accomplished by first creatinghollowed out regions within the structural units that meet at a jointthat is to be sealed with a fire resistant barrier. The fire resistantbarrier, which consists of a thin layer of material of appropriatehigh-temperature properties, is then inserted into both hollowed gaps atthe ends of the adjacent structural units. Thus, the widening ornarrowing or shear motion of the adjacent plates is accommodated by thefire resistant barrier moving in a sliding fashion within the adjacentstructural units. As long as the lateral dimensions of the barrierexceed the widest distance between the adjacent structural units duringdifferential movement, the integrity of the barrier should remain.Similarly, when the structural units move together, the barrier shouldremain undamaged providing that the lateral dimension of the barrier isless than the distance between the bottoms of the hollowed out regionsof the structural units. The major drawback of this approach is that thefire resistant material must be thin enough to fit within the hollowedout areas of the adjacent structural units. However, fabricating thehollowed out areas further complicates the construction of the buildingand increases the cost of the construction. Moreover, correctinstallation of such a barrier in a pre-existing building is difficultand expensive.

On the other hand, fire resistant materials can be fabricated into thin,flexible fibers which can be incorporated into flexible, fire resistantstructures resembling a blanket. The advantages of such a material arethat the fabrication is not very expensive, the draping of the blanketacross a joint is readily accomplished and any differential movement ofthe adjacent structural units can be accommodated by incorporating anappropriate amount of slack in the blanket during installation. Theblanket, however, is mechanically weak and can be easily damaged bytearing or ripping either accidentally or intentionally during or afterinstallation thus largely compromising the integrity of the fireresistant barrier. A number of attempts have been made to protect theblanket from such mechanical damage. These have generally relied on thefabrication of a composite blanket which incorporates the fire resistantmaterial between layers of a stronger, protective material such as metalfoils or metal screens. The fire resistant layer can freely move withrespect to these protective layers or they may be attached together viathreads or similar attaching means.

Given the wide variety of movements that may occur between structuralelements in a building, particularly one situated in a seismicallyactive region, there still remains the possibility of gaps appearing inthe fire barrier. To reseal these gaps in the event of a fire,intumescent materials are frequently added to the barrier. These arematerials that expand when rapidly heated and at the same time have fireresistant properties. Thus, these provide a second method of sealing thestructural gap in a building.

Attempts have been made to provide for sealing the dynamic joints thatoccur between structural units in a building. All of these solutionsonly provide for a fire barrier that is designed to obstruct air flowthrough a gap that occurs only between two building structures, such asthe gap that occurs at the join of two walls. Many expansion joints,however, occur at the juncture of more than two building structures,such as where four walls meet to create a cross-wise gap, or where twoexterior walls and an interior wall meet creating a “T”-shaped gap.Presently, there is no system which is capable of sealing a gap betweenmore than two structural units in a building. None of the previouslydescribed fire barrier assemblies is capable of bridging the kind ofmulti-dimensional gap that occurs at the convergence of a plurality ofstructural units.

Thus, it is clear that what is sorely lacking in the art is a firebarrier that can accommodate that important safety need. It would be asignificant improvement in the art to provide a fire barrier that isdesigned to provide a multi-pathway air flow obstacle. Ideally, thenovel multi-dimensional fire barrier would ideally be constructed as aone piece, ready to install, unit to better ensures the integrity of thebarrier when stressed and to allow for quicker and easier installationthan would a multi-piece multi-dimensional fire barrier.

Accordingly, the invention described herein addresses this heretoforeunmet need.

SUMMARY

The present invention satisfies the pressing need for means to preventthe rapid spread of flames, heat, and smoke throughout a structurecaused by the “chimney effect,” that is, the updraft created bymulti-dimensional structural gaps.

The unique fire barrier structures as described herein offer firebarriers sized and designed to fit into multi-dimensional expansionjoints occurring at the junction of more than two structures. Thebarriers made be provide ready to assemble or ready to install. Onepreferred version of the invention comprises a barrier made using athree layer construction that includes a layer of protective cloth, aninsulating material layer (insulation blanket), and an intumescentmaterial layer. The three layers are affixed together to form afundamental layer using high-temperature resistant means. This barrieris not, however, the typical strip-type barrier that consists of one ormore fire resistant layers simply superimposed one over the other.

The fire barrier of the present invention is unique in several ways. Onepoint of novelty is the variety of three-dimensional configurations thatcan be accomplished using the fundamental layer regardless of the numberor kinds of layers used to construct the fundamental layer. For example,in one aspect, the fundamental layer of the barrier is shaped into aunitary multi-dimensional barrier that is to be inserted directly into acorner expansion joint. Another aspect is a multi-dimensional barrierthat fits into a “T” shaped space created by the convergence of threebuilding structures, such as three walls, for example. In yet anotheraspect, a unitary multi-dimensional fire barrier is functionallydesigned to be fitted into the cross-wise or 4-way shaped expansionjoints that are created by the confluence of four building structures,such as when four walls meet, for example. An additional aspect is amulti-dimensional fire barrier that fits into a vertical/horizontal 90degree expansion joint. Another alternative is a multi-dimensional firebarrier that is operative for use in an expansion joint comprising a 45degree angle. Yet another alternative multi-dimensional fire barrier isdesigned for use in a T-shaped joint having an additional joint thatcomes in at a right angle to the T-shaped expansion joint.

Yet another unique feature of the present invention is that regardlessof the type of multi-dimensional expansion joint system that the firebarrier is intended to fit, all of the barriers are designed to havemovement and expansion capabilities. Additionally, each of the materialsused in the construction of the fire barriers meet UnderwritersLaboratory, Inc. required specifications for materials used in a jointsystem.

Thus, the invention as described make available the above describedadvantages by providing for multi-dimensional fire barriers for use inmulti-dimensional architectural expansion joints, wherein the firebarriers may comprise a plurality of fire resistant material layers. Thefire resistant material layers may be connected together by stitching,stapling, using pins and bolts, using adhesive, or by any other bondingor connection method.

The multi-dimensional fire barriers, as taught may be operativelymanufacture for use in a corner junction expansion joint, a “T’-shapedexpansion joint, or in a 4-way expansion joint, a vertical/horizontal 90degree expansion joint, an expansion joint comprising a 45 degree angle,and a T-shaped joint having an additional joint that comes in at a rightangle to the T-shaped expansion joint, for example.

The multi-dimensional fire resistant barriers, according to theprinciples of the present invention may further comprise a plurality offire resistant material layers including at least one mechanical supportlayer, at least one insulating layer, and at least one layer ofintumescent material, wherein the insulating layer is disposed betweenthe mechanical support layer and the one intumescent layer; and wherethe layers are bonded together substantially continuously along their toprovide for multi-dimensional fire barriers operatively adapted forfitting into multi-dimensional architectural expansion joints.

The mechanical support and protective layer may be made from continuousfilament amorphous silica yarns, polymeric material, fiber reinforcedpolymeric material, metallized fiber reinforced polymeric material,metallized, fiberglass cloth material, or inorganic fiber clothmaterial. The inorganic fibers may be selected from glass or ceramicfibers.

The insulating layer may be made from refractory ceramic fiber that mayconsist of alumina-silica, polycrystalline mullite, or glass matmaterials.

The intumescent layer of the multi-dimensional fire barriers, may beselected from the group consisting of unexpanded vermiculite,hydrobiotite, water-swelling tetrasilicic fluorine mica, expandablegraphite, or mixtures thereof. The intumescent layer may comprise ablend of fibers, wherein said fibers are selected from the groupconsisting of refractory ceramic fibers, high-temperature resistantglass fibers, or unexpanded vermiculite.

The method for making the multi-dimensional fire barriers comprises thesteps of:

-   -   a) providing for at least one mechanical support layer;    -   b) providing for at least one insulating layer, and    -   c) providing for at least one layer of intumescent material,    -   d) disposing the insulating layer between the mechanical support        layer and the intumescent layer; and    -   e) bonding the layers together substantially continuously along        their lengths to provide for multi-dimensional fire barriers        operatively adapted for fitting into multi-dimensional        architectural expansion joints.

Further preferred embodiments, include fire barriers for installationinto spaces formed by the intersection of architectural expansion jointscomprising approximately right-angled, acute-angled, and obtuse-angledintersections of at least two architectural expansion joints, comprisingfire barriers for installation into flue-like fire, heat, and smokefunneling spaces formed by the angled intersections of at least twoarchitectural expansion joints, comprising:

fire resistant barriers comprising a plurality of fire resistantmaterial layers including:

-   -   a first layer comprising:        -   a fire resistant protective cloth sheet having a first and            second surface, and        -   a first fire resistant insulation blanket sheet having a            first and second surface, the second surface of said            protective cloth sheet positioned under and contiguous to            the first surface of the first insulation blanket sheet            providing protection and mechanical support for the fire            barrier;        -   at least one layer of a first fire resistant intumescent            material sheet arranged on the second surface of the first            insulation blanket sheet;        -   a first fire resistant resilient mechanical support sheet            having a first and second surface, the first surface of said            first resilient mechanical support sheet positioned over the            second surface of the first insulation blanket having a            layer of the intumescent sheet, and    -   a second layer comprising:        -   a second fire resistant insulation blanket sheet having a            first and second surface,        -   at least one layer of a second fire resistant intumescent            material sheet arranged on the second surface of the second            insulation blanket sheet, and        -   a second fire resistant resilient mechanical support sheet            having a first and second surface, the first surface of the            second resilient mechanical support sheet positioned over            the second surface of the second insulation blanket having a            layer of the second intumescent sheet;

the second layer positioned over the first layer so that the firstsurface of the second insulation blanket is positioned over the secondsurface of the first resilient mechanical support sheet,

the layers locally bonded together forming a unitary layered firebarrier ready for installation within the spaces formed by the expansionjoints intersecting at angles for affixation to the building structuralunits forming said expansion joints providing for a barrier against thetravel of fire, heat, or smoke through the flue-like expansion joints ofa structure.

In still furthermore preferred embodiments, the protective cloth of thefire barriers further includes mounting means for affixing the layeredfire barrier to the building structural units, wherein the mountingmeans comprise flanges attached to the side edge portions of theprotective cloth, and wherein the mounting means further comprise aplurality of fasteners used in conjunction with the flanges providingfor the fire barrier to be affixed to the building structural units, andfurther comprising wherein the plurality of fasteners further comprisesa plurality of pins and washers.

The invention as described further comprises a reusable mounting toolfor depositing said fire barrier within said expansion joints foraffixation to said building structural units; said at least one reusablemounting tool comprising a rigid frame that is reversibly attachable toeach of said fire barriers using reversible attachment means, such as,but not limited to pins and washers, and where each frame has at leastone grasping means, such as a handle on the frame providing for easylifting and positioning of the frame along with the fire barrier that isreversibly attached to the frame into said expansion joints. The widthof the mounting tool is adjustable to accommodate the width of the firebarrier, which accommodates the width of the expansion joints that areintersecting at 90 degrees. Moreover, the reusable mounting tools areavailable in a kit of mounting tools containing installation tool framesfor installation of various sized and shaped fire barriers into varioussized and shaped spaces formed by the intersection of architecturalexpansion joints comprising angled intersections of at least twoarchitectural expansion joints.

A preferred embodiment includes wherein the fire resistant barrier iscontoured in the form of a cross for fitting into a planar intersectionof four architectural expansion joints, a T-shape for fitting into aplanar angled intersection of three architectural expansion jointsarchitectural expansion joints, an L-shape for fitting into a planarangled intersection of two architectural expansion joints, and anL-shape for fitting into a non-planar angled intersection of twoarchitectural expansion joints, wherein the non-planar angledintersection of two architectural expansion joints, comprises anintersection of an vertically oriented expansion joint with ahorizontally oriented expansion joint.

Also included in the preferred embodiment are methods for installingfire barriers into fire, heat, and smoke funneling spaces formed byessentially angled intersections of at least two architectural expansionjoints, comprising the steps of:

providing for fire resistant barriers comprising a plurality of fireresistant material layers including:

-   -   a first layer comprising:        -   a fire resistant protective cloth sheet having a first and            second surface, and        -   a first fire resistant insulation blanket sheet having a            first and second surface, the second surface of the            protective cloth sheet positioned under and contiguous to            the first surface of the first insulation blanket sheet            providing protection and mechanical support for the fire            barrier;        -   at least one layer of a first fire resistant intumescent            material sheet arranged on the second surface of the first            insulation blanket sheet;        -   a first fire resistant resilient mechanical support sheet            having a first and second surface, the first surface of the            first resilient mechanical support sheet positioned over the            second surface of the first insulation blanket having a            layer of the intumescent sheet, and    -   a second layer comprising:        -   a second fire resistant insulation blanket sheet having a            first and second surface,        -   at least one layer of a second fire resistant intumescent            material sheet arranged on the second surface of the second            insulation blanket sheet, and        -   a second fire resistant resilient mechanical support sheet            having a first and second surface, the first surface of said            second resilient mechanical support sheet positioned over            the second surface of said second insulation blanket having            a layer of the second intumescent sheet;

positioning said second layer over said first layer so that the firstsurface of the second insulation blanket is positioned over said secondsurface of the first resilient mechanical support sheet,

bonding said layers locally together forming a unitary layered firebarrier ready for installation within the spaces formed by saidexpansion joints intersecting at angles for affixation to the buildingstructural units forming the expansion joints intersecting at anglesproviding a barrier against the travel of fire, heat, or smoke throughthe expansion joints of a structure.

Still other benefits and advantages of this invention will becomeapparent to those skilled in the art upon reading and understanding thefollowing detailed specification and related drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that these and other objects, features, and advantages of thepresent invention may be more fully comprehended, the invention will nowbe described, by way of example, with reference to the accompanyingdrawings, wherein like reference characters indicate like partsthroughout the several figures, and in which:

FIG. 1 is a plan view illustrating a template used in the cutting andsewing of protective cloth used in the construction of themulti-dimension fire barrier in accordance with the teachings of thisinvention so as to produce a cloth to accommodate an expansion jointthat comprises a corner junction without having excess cloth bulk orcausing tearing of the cloth.

FIG. 2 is a plan view looking down on one part of a multi-dimension firebarrier that is to be fitted into protective cloth that has been foldedand seamed for installation into a 90 degree expansion joint.

FIG. 3 is a perspective view looking down on and into a multi-dimensionfire barrier ready for installation in a 90 degree expansion joint asshown in FIG. 2.

FIG. 4 is a cross-sectional view of a multi-dimension fire barrierinstalled in a 90 degree expansion joint as illustrated in FIG. 3 toshow how stitching may be used to connect the layers.

FIG. 5 is a plan view looking down onto unfolded Part 1 (i.e., thebase-part) of a multi-dimension fire barrier to be installed in a “T”shaped expansion joint.

FIG. 6 is a perspective view of folded Part 1 as shown in FIG. 5.

FIG. 7 is a perspective view of unfolded Part 2 of the multi-dimensionfire barrier to be installed in a “T” shaped expansion joint.

FIG. 7 a is a perspective view of the “T” shaped expansion fire barrierready for installation.

FIG. 8 is a plan view looking down onto the unfolded base-part of amulti-dimension fire barrier to be installed in a 4-way expansion joint.

FIG. 9 is a perspective view of the folded base-part as shown in FIG. 8.

FIG. 10 is a plan view looking down onto an unfolded second part of a4-way fire barrier.

FIG. 11 is a plan view illustrating a template used in the cutting andsewing of the protective cloth used in the construction of avertical/horizontal 90 degree fire barrier so as to produce a cloth tofit around an expansion joint that comprises a vertical/horizontal 90junction without having excess cloth bulk or causing tearing of thecloth.

FIG. 12 is a plan view looking down onto a vertical/horizontal 90 degreefire barrier before it has been cut, folded, or stitched.

FIG. 13 is a perspective view of the vertical/horizontal 90 degree firebarrier, as shown in FIG. 12, prepared for installation.

FIG. 13 a is a perspective view of the vertical/horizontal 90 degreefire barrier, as shown in FIG. 12, seamed by the use of pins and bolts.

FIG. 14 is a plan view of a template used in the cutting and sewing ofthe protective cloth used in the construction of a horizontal 45 degreefire barrier so as to produce a cloth to fit around an expansion jointthat comprises a horizontal 45 junction without having excess cloth bulkor causing tearing of the cloth.

FIG. 15 is a plan view looking down onto a horizontal 45 degree firebarrier prepared for installation.

FIG. 16 is a perspective view of the horizontal 45 degree fire barrier,as shown in FIG. 15, ready to be installed.

FIG. 17 is a plan view of a template used in the cutting and sewing ofthe protective cloth used in the construction of a horizontalT-joint/vertical fire barrier so as to produce a cloth to fit around ahorizontal T-joint/vertical expansion joint without having excess clothbulk or causing tearing of the cloth.

FIG. 18 is a plan view looking down onto an unfolded insulation blanketwith intumescent material positioned on the insulation blanket ready forfitting into a protective cloth cut and sewn to fit into a horizontalT-joint/vertical expansion joint fire barrier.

FIG. 18 a is a perspective view of the cut, folded, and seamed firebarrier sized and shaped to fit a horizontal T-joint/vertical expansionjoint with the insulation blanket and intumescent material, as shown inFIG. 18 positioned in the cut, folded, and seamed fire barrier.

FIG. 18 b is a plan view of the template that is used to cut theprotective cloth that is to be positioned under and about the T-shapedextension arms as illustrated in FIG. 18 a.

FIG. 19 is a perspective view of the four additional insulationblanket/intumescent material parts that will complete the side walls forthat part of the horizontal T-joint/vertical expansion joint firebarrier. These pieces are to be inserted inside of the protective clothcoverings (i.e., shown as a template in FIG. 18 b. The T-shapedstructure (as is shown in FIG. 18.) is in the figure only as a guide forthe placement of the insulation blanket/intumescent material parts. Thisstep will complete the assembly of the horizontal T-joint/verticalexpansion joint fire.

FIG. 19 a is a perspective view of a horizontal T-joint/verticalexpansion joint fire barrier installed in a model horizontalT-joint/vertical expansion joint structure. In this illustration theintumescent strip layer is about to be positioned on the insulationblanket. The barrier is shown temporarily attached to the modelstructure with clamps.

FIG. 20 is a plan view of four schematic multi-dimensional expansionjoints.

FIG. 21 is a perspective view of the novel work form that is requiredfor the seaming of a fire barrier that is shaped and sized to fit into a90° expansion joint structure.

FIG. 21 a is another perspective view of the novel work form that isrequired for the seaming of a fire barrier that is shaped and sized tofit into a 90° expansion joint structure.

FIG. 22 a is an exploded view of a layered fire barrier comprising onevertical arm and one horizontal arm, which arms provide for the barrierto fit into an expansion joint space defined by the angled intersectionof a vertically oriented expansion joint and a horizontally orientedexpansion joint.

FIG. 22 b is a perspective view of the exploded layers illustrated inFIG. 22 a positioned within one another.

FIG. 23 a is a perspective view illustrating the structural relationshipbetween the fire barrier, the support/attachment strips that may be usedto attach an installation tool to the barrier as shown in FIG. 22 b, andthe installation tool.

FIG. 23 b is a perspective view illustrating the positioning of pinsthrough the barrier and the stripping so that the pins along with washeract to reversibly affix the installation tool to the barrier.

FIG. 23 c is perspective view illustrating the installation toolreversibly affixed to the fire barrier which is now ready for a one-stepdrop-in installation into an expansion joint.

FIG. 23 d is a perspective view of the fire barrier installed into thespace formed by a vertical/horizontal expansion joint with itsinstallation tool remaining attached to the barrier until the barrier isfixedly attached to the building units that define thevertical/horizontal expansion joint.

FIG. 23 e is a perspective view of the fire barrier as illustrated inFIG. 23 d illustrating the attachment means used to fixedly attach thebarrier to the building units.

FIG. 23 f is a perspective view of the fire barrier as illustrated inFIG. 23 e illustrating the barrier fixedly attached to the buildingunits with its installation tool removed.

FIG. 24 a is a perspective view illustrating a cross-shaped firebarrier.

FIG. 24 b is a perspective view illustrating a cross-shaped fire barrierwith its unique installation tool attached.

FIG. 25 a is a perspective view illustrating a T-shaped fire barrier.

FIG. 25 b is a perspective view illustrating a T-shaped fire barrierwith its unique installation tool attached.

FIG. 26 a is a perspective view illustrating an L-shaped fire.

FIG. 26 b is a perspective view illustrating an L-shaped fire barrierwith its unique installation tool attached.

FIG. 27 is a cross-sectional view of a fire barrier and its installationtool in place illustrating how the barrier layers are attached to eachother and how the barrier's installation tool is attached to thebarrier.

FIG. 28 is a perspective view of a kit containing all of theinstallation tools required for the installation of all of the barriersof the present invention and the spacers that provide for each tool tobe used with fire barriers made to fit into expansion joints of variouswidths.

DEFINITIONS

Angled, as used herein, refers to acute, obtuse, right-angled, andnearly, or approximately right-angled. The term “angled” is used hereinmostly to refer to the configuration formed when architectural expansionjoints (which may be referred to as spaces), building units, orextensions (or as referred to as “arms”) of fire barriers intersect ormeet at a common place.

Intumescent as used herein refers to those materials having propertiesthat cause that material to expand when heated.

Insulation blanket as used herein refers to any number of insulatormaterials, including fiber blankets made from alumina, zirconia, andsilica spun ceramic fibers, fiberglass, and the like.

High-temperature thread as used herein refers to any thread that is fireresistant or any thread that will not support combustion, such as aceramic thread.

Multi-dimensional architectural expansion join” as used herein refers toany joint that is formed by the convergence of more than two structuralunits, such as the convergence of three wall units or two walls and afloor unit.

Multi-dimensional fire resistant barrier as used herein refers to anyfire barrier that is functionally shaped to functionally fit into amulti-dimensional architectural expansion joint.

Protective Cloth as used herein refers to a flexible, strong,protective, fire-resistant material that is designed to mechanicallysupport the insulation material and to protect the insulation materialfrom mechanical damage, as the insulation is mechanically weak and canbe easily damaged by tearing or ripping either accidentally orintentionally during or after installation thus largely compromising theintegrity of the fire resistant barrier. The fire resistant layers, suchas a layer of insulation material together with a layer of intumescentmaterial, can freely move with respect to the one or more protectivelayers or they may be attached together via threads or other attachingmeans. Protective cloths may be manufactured from continuous filamentamorphous silica yarns, polymeric material, fiber reinforced polymericmaterial, high-temperature resistant woven textiles, or a metalized,fiberglass cloth. Metalized cloth may include fibers of stainless steel,aluminum, or copper, for example. Protective materials may also includemetal foils or metal screens.

Seaming as used herein refers to connecting one part to another part,for example where a cloth is folded and the two parts of the cloth thathave been brought together by the folding are subsequently “seamed”together along a predetermined line. The seaming may utilize stitching,using an adhesive, stapling, pinning, or any other means that willconnect the two parts to each other.

Stripping, as used herein, refers to off-the-shelf non-flammablestripping used in construction and fabrication for holding, binding,and/or attaching.

Structural unit as used herein refers to such constructs as a wall,floor, ceiling, or the like.

Tri-dimensional as used herein refers to either an expansion joint thathas three member parts, such as a “T”-shaped expansion joint where the“T”-joint is made up of three co-joint-arms or to a fire barrier that isfunctionally shaped to accommodate a “T”-shaped joint.

Tetra-dimensional as used herein, refers to either an expansion jointthat has four member parts, such as a cross-shaped expansion joint wherethe cross-joint is made up of four co-joint-arms or to a fire barrierthat is functionally shaped to accommodate a cross-shaped joint.

Vertical/horizontal fire barrier, as used herein, refers to a unitarystructure fire barrier comprising one vertical arm and one horizontalarm, which structure provides for the barrier to fit, as a one-piecedrop-in unit, into an expansion joint space defined by the 90°intersection of two expansion joints, one vertical joint and onehorizontal joint.

A LIST OF THE REFERENCE NUMBERS AND RELATED PARTS OF THE INVENTION

-   20 Intumescent strip material.-   22 High-temperature thread.-   30 Protective cloth.-   32 Protective cloth flange.-   40 First insulation blanket.-   42 Second insulation blanket.-   (S) Stitching-   (PC) Protective cloth.-   50 First non-flammable supporting mesh.-   52 Second non-flammable supporting mesh.-   60 Non-flammable strapping.-   70 Friction-fit washer to attach fire barrier to building unit 90.-   70B Friction-fit washer to attach fire barrier sheets to each other    to form a layer.-   70T Friction-fit washer to attach installation tool to related fire    barrier.-   72 Pin to attach fire barrier to building unit 90.-   72B Pin to attach fire barrier sheets to each other to form a layer.-   72T Pin to attach installation tool to related fire barrier.-   73T Head of pin 72T.-   74 Spacer.-   76 Fasteners to attach fire barrier to building unit 90.-   76B Fasteners to attach fire barrier sheets to each other to form a    layer.-   76T Fasteners to attach installation tool to related fire barrier.-   80 A vertical expansion joint.-   82 A horizontal expansion joint.-   90 Building unit.-   100 Installation tool.-   110 Vertical/horizontal fire barrier.-   200 Installation tool.-   220 Two-way or L-shaped fire barrier.-   300 Installation tool.-   330 Three-way or T-shaped fire barrier.-   400 Installation tool.-   440 Four way or cross-shaped fire barrier.-   102 Width determining exchangeable installation tool segments.-   104 Tool frame-   106 Tool grasping means.-   500 Kit providing all of the basic parts required to construct a    desired installation tool and the tools used in the tool    construction and in reversibly attaching and detaching an    installation tool from a fire barrier.-   502 Storage compartments.-   503 Allen wrenches for assembling and changing width of installation    tools.-   504 Installation tool frame segments.-   505 A set of width determining exchangeable installation tool    segments.-   510 Joining means for joining segments 504 for assembling    installation tools.

It should be understood that the drawings are not necessarily to scale.In certain instances, details which are not necessary for anunderstanding of the present invention or which render other detailsdifficult to perceive may have been omitted. It should be understood, ofcourse, that the invention is not limited to the particular versionsillustrated herein, but encompasses many embodiments, such as those thatare discussed throughout the specification. Expansion jointintersections occur in many configurations, as all of thoseconfigurations entail various combinations of vertical, horizontal, andcorner joints, it will be appreciated that all of the configurations areembodied by this invention.

DETAILED DESCRIPTION

Referring now particularly to the drawings which show views of exemplaryversions of some of the templates that are contemplated by thisinvention. The drawings also illustrate how the above mentioneddisadvantages have been overcome. It should be noted that the disclosedinvention is disposed to versions in various sizes, shapes, contents,and forms. Therefore, the versions described herein are provided withthe understanding that the present disclosure is intended asillustrative and is not intended to limit the invention to the versionsdescribed herein.

Fire barriers are often, but not necessarily, constructed ofthree-layers; a thick insulation layer, an intumescent layer, and aprotective cloth layer where the protective cloth is used to prevent themore susceptible insulation blanket from suffering physical damage, suchas tearing. One preferred method of constructing the multi-dimensionalfire barriers of this invention is to use the three-layer constructionmethod, although it should be understood that many other methods andmaterials may also be used.

Many variations of structural multi-dimensional expansion joints exist.FIG. 20 illustrates the basic one-dimensional, straight expansion jointand three multi-dimensional expansion joints. An example of onepreferred version of the multi-dimensional fire barriers taught hereinis an L-shaped fire barrier that fits into corner expansion joints. Toconstruct the three-layered L-shaped fire barrier, protective cloth,which is one of the three-layers, is cut according to the templateillustrated in FIG. 1 and then stitched along the “sew line.” Thisassembly method produces a protective cloth jacket that fits neatly intoa 90 degree junction expansion joint with tearing. Protective cloth,although strong and somewhat flexible, is often rigid enough to be proneto tearing when stressed by bending, such as by being forced to achievea corner shape. Additionally, if the relatively thick protective clothis folded to fit a corner without first shaping the cloth, as taughtherein, an unacceptable bulky product will be produced. However, whenthe protective cloth is cut, folded, and seamed according to the patternprovided by the principles of this invention a custom-shapedmulti-dimension L-shaped fire barrier without excess bulk is produced.Moreover, this unique method of shaping the protective cloth of thebarrier eliminates the stresses on and potential for tearing of theprotective cloth. The protective cloth may be seamed by stitching usinga high-temperature thread, such as filamentous fused silica, forexample. The L-shaped protective cloth cut, folded, and sewn accordingto this method is now ready to be used in the construction of a 90degree expansion joint fire barrier unit. The protective cloth part,thus shaped, will be referred to as the first part of the L-shapedbarrier.

The second part of the L-shaped barrier as shown in FIG. 2, comprisesthe other two layers of the three-layer construction. In this example, alayer of intumescent material 20 strip-layers are positioned oninsulation blanket layer 40, as shown. The two layers may be connectedby stitching using high-temperature thread 22 at this point or they maybe stitched together with the protective cloth after the following step.

FIG. 3 is a perspective view looking down on and into a multi-dimensionfire barrier preformed and ready to be installed in a 90 degreeexpansion joint. As can be seen, the insulation blanket and theintumescent strips, as shown in FIG. 2 have been placed into theL-shaped protective blanket. The three-layers are affixed together atthis point by sewing or by any other desired fixation means, such as bystapling or by using pins and washers as illustrated in FIG. 3. As canbe seen, the more easily damaged insulation blanket and the intumescentstrips are supported and protected by the shaped layer of protectivecloth. The intumescent material, which expands when a certainhigh-temperature is reached, is functionally positioned to provide themaximum amount of protection against the penetration of heat, flame, orsmoke. The intumescent expansion prevents the passage of heat, flame, orsmoke though openings that may have existed before being blocked by theswollen intumescent.

As is shown in FIG. 4, the stitching that attaches the intumescentmaterial to the blanket goes through the intumescent strips, theblanket, and the protective cloth, so that all three-layers are attachedtogether to provide a unitary functional unit. Once the L-shaped firebarrier is situated in a 90 degree expansion joint it may be attached tothe structural unit in a variety of ways, such as by riveting thefold-out portions of the protective blanket (as shown in FIG. 3) to thetop of the structure.

Another expansion joint configuration that occurs frequently is theT-shaped expansion joint which occurs when three structures meet, suchas the convergence of three walls. FIG. 5 shows the base part of acustom sized and styled T-shaped fire barrier. Also illustrated in FIG.5 is the three-layer construction that was also used in the L-shapedfire barrier. It must again be pointed out, however, that othermaterials and other constructions may be used in the manufacture of afire barrier. The novelty of this invention resides mainly in providingmulti-dimensional fire barrier structures regardless of the materialsused to make the structures, and in teaching the methods of making thecustom-fit and custom-sized multi-dimensional fire barriers, where thefire barriers are produced as ready to install one-piece units, or ifdesired, may be provided unassembled to be assembled on-site. As shownin FIG. 5, strips of intumescent material 20 are functionally positionedon the surface of insulation blanket 40, which in turn is functionallypositioned on protective cloth 30. Intumescent layer 20, insulationblanket 40, and protective cloth 30 are fixedly attached together toform an integral unit. In this example, the fixation is accomplished bystitching, as was shown in FIG. 4, using a high-temperature thread,although the fixation may be accomplished by any other fixation means,including staples and adhesive, for example. To prepare unfolded Part 1(i.e., the base of the barrier), as illustrated in FIG. 5, for its unionwith Part 2 (i.e., the attachment part) as illustrated in FIG. 7, thetop and bottom end of Part 1 (the base) are folded toward each otherabout the two fold lines shown in FIG. 5. Shown situated on each side ofthe “T” flap of the base, FIG. 5, are two extensions of insulatorblanket 40. The inner edges of the two extensions of the insulatorblanket, that is, the edges that border each side of the “T” flap, areconstructed to be physically separate from the “T” flap (i.e., cut loosefrom the “T” flap) so that the “T” flap can be maintained in its foldedout position while the two insulator blanket extensions along with theprotective cloth extensions (denoted PC) are folded up, as is shown inFIG. 6.

FIG. 7 is a plan view looking down onto an unfolded second part (theattachment part) of a T-shaped multi-dimension fire barrier. To preparePart 2 (the attachment part) for connection to Part 1 (the basesection), the two side walls of Part 2 are folded up towards each otherat the fold lines shown in the figure. Once this is accomplished, Part 2is positioned so that the “T” flap support part of the base part isplaced under the “T” flap of the attachment part. With Part 2 (theattachment part) so positioned, the folded-up side walls of Part 2 (thebase part) provide side walls for the “T” flap extension of the T-shapedfire barrier. Finally, the fold-out portions are folded out to be usedfor attaching the fire barrier to the structure parts of the expansionjoint.

FIG. 7 a, a perspective view of the “T” shaped expansion fire barrierready for installation, illustrates the completely fabricated firebarrier with the addition of protective metal screening, which can beshipped directly to the construction site to be positioned in place. Thebarrier is permanently attached to the joint structure by any effectiveattachment means, such as by the use of rivets. The figure shows the useof clamps as the means to attach the barrier to the model expansionstructure.

Another common multi-dimensional expansion joint configuration is thatof the 4-way or cross-shaped joint. This joint occurs where fourstructures converge, such as the convergence of four walls, for example.How to make a fire barrier custom styled and sized for any 4-wayjunction is shown in FIGS. 8-10.

FIG. 8 shows the base part of a 4-way fire barrier. As in the otherexamples, this example also employs three-layer construction, where thelayers comprise an intumescent strip layer positioned on a layer ofinsulation material, which in turn is positioned on a layer ofprotective cloth. The three-layers are connected together by stitching(as shown in FIG. 4), where the stitching is accomplished usinghigh-temperature thread. The design of the base part of the 4-way firebarrier uses the principals of the T-shaped fire barrier. In fact, theconstruct of the “T” flap end of the base part of the T-shaped firebarrier is simply followed on the two opposing ends of the base part ofthe 4-way fire barrier instead of on only one end of the base as is donein the T-shaped fire barrier.

Situated on each side of the two 4-way Flaps of the protective clothbase of the 4-way barrier are two extensions of insulator blanket 40.The inner edges of the two extensions of the insulator blanket, that is,the edges that border each side of the “T” flap, are constructed to bephysically separate from the “T” flap, so that the “T” flap is kept openflat while the two insulator blanket extensions along with theprotective cloth extensions (denoted PC) are folded up, as is shown inFIG. 9. The protective cloth extensions are subsequently folded out tobe used for attaching the fire barrier to the structure parts of theexpansion joint.

Shown in FIG. 9 is the 4-way base folded up and out ready for theaddition of the attachment parts. Note that in the case of the 4-wayfire barrier there are two attachment parts. FIG. 10 illustrates oneattachment part. Only one attachment part is shown in FIG. 10 as the twoattachment parts required in the construction of a 4-way fire barrierare identical to each other and to the attachment part used in theT-shaped fire barrier. As in the T-shaped fire barrier, the “flapsupport” parts of the attachment parts (Part 2 in the T-shaped firebarrier) are each inserted beneath one of the two 4-way flaps. In thisway, as in the previous example, insulator parts 20 then are in positionto form the side barriers of the 4-way flap extensions. Once the twoattachments are in position, as just described, the 4-way fire barrieris ready for installation in a 4-way extension joint.

FIG. 11 shows a plan view of a template used to cut and sew protectivecloth to construct a vertical/horizontal 90 degree fire barrier to fit avertical/horizontal 90 degree junction expansion joint without havingexcess cloth bulk or causing tearing of the cloth. The template teachesfour cut lines. Once these cuts are made in the protective cloth shapedaccording to the template, the cloth is folded about the four fold-outlines and two fold-in lines. The cloth is also to be folded about thetwo pair of angled pattern lines and then seamed, such as by being sewntogether, for example, using the pattern lines as a stitching guide. Thecutting, folding, and sewing of the protective cloth, as just described,results in the cloth assuming a chair-like shape, where the chair hasarm-like and wing-like extensions. These extensions will be used toattach the finalized fire barrier to the structures. As in the previousexamples, if stitching is the connection means used, high temperaturethread is employed.

FIG. 12 is a plan view looking down onto a protective cloth patternedfor cutting, folding, and seaming according to the vertical/horizontal90 degree fire barrier template as illustrated in FIG. 11. In thedesignated (see FIG. 11) mid-area an insulation blanket has beenpositioned. Positioned on the edge surface area of the insulationblanket is a layer of intumescent stripping material. As in the previousexamples, the three layers are connected together by stitching with hightemperature thread.

FIG. 13, a perspective view, shows the cut, folded, and sewnvertical/horizontal 90 degree fire barrier ready for installation in avertical/horizontal 90 degree expansion joint. FIG. 13 a shows thebarrier seamed by the use of pins and bolts “installed” in a modelvertical/horizontal 90 degree expansion joint. In this figure, thebarrier is attached to the model expansion by clamps. In will beappreciated, that in an actual structure the barrier is permanentlyinstalled using any functional attachment means, such as rivets.

FIG. 14 is a plan view of a template used in the folding and seaming ofprotective cloth used in the construction of a horizontal 45 degree firebarrier so as to produce a cloth to fit around an expansion joint thatcomprises a horizontal 45 junction without having excess cloth bulk orcausing tearing of the cloth. Cutting is not required to achieve thehorizontal 45 degree fire barrier. In this example, the protectivecloth, once cut to conform to the template, as shown, is folded andseamed along the fold and stitch lines and then folded up along theinner set of the fold lines and folded out along the outer set of foldlines. At this point, the protective blanket is ready for the additionof a layer of insulation blanket and a layer of intumescent material.

FIG. 15 is a plan view looking down onto a horizontal 45 degree firebarrier with attached layers of insulation blanket and intumescentmaterial ready for installation in a the horizontal 45 degree expansionjoint.

FIG. 16 is a perspective view of one end of the horizontal 45 degreefire barrier, as shown in FIG. 15, ready to be installed.

FIG. 17 is a plan view of a template used in the cutting, folding, andsewing of the protective cloth used in the construction of a horizontalT-joint/vertical fire barrier so as to produce a cloth to fit around ahorizontal T-joint/vertical expansion joint without having excess clothbulk or causing tearing of the cloth. The lines that are to be used ascutting guides, are Illustrated in FIG. 17, as the lines marked withcircles, whereas the lines that to be used as the pattern for foldingand seaming are the lines marked with “X”s. The plain lines are guidesfor folding only. As seen in the figure, the T-shaped area on which asuitable shaped insulation blanket is to be placed is marked according.Once the cloth has been cut, folded, and seamed according to thetemplate as illustrated in FIG. 17,

FIG. 18 is a plan view looking down onto an unfolded, but T-shapedinsulation blanket with an intumescent material layer positioned on theinsulation blanket layer. These two layers are ready for fitting into aprotective cloth cut and sewn following the horizontal T-joint/verticalfire barrier template as illustrated in FIG. 17.

FIG. 18 a, a perspective view of the cut, folded, and seamed firebarrier sized and shaped to fit a horizontal T-joint/vertical expansionjoint with the insulation blanket and intumescent material, as shown inFIG. 18 positioned in the cut, folded, and seamed fire barrier, showsthe partially assembled barrier ready for the protective cloth, cutaccording to the template illustrated in FIG. 18 b, to be positionedunder and about the T-shaped extensions.

FIG. 18 b is a plan view of the template that is used to cut the twopieces of protective cloth, where each piece is to be positioned underand about the extended T-shaped extension arms, as illustrated in FIG.18 a. This addition provides a protective and supportive layer to holdthe insulation blanket/intumescent material layers that are to beinstalled next.

FIG. 19 is a perspective view of the four additional insulationblanket/intumescent material parts that will complete the layered sidewalls for the T-shaped extension arm part of the horizontalT-joint/vertical expansion joint fire barrier. The insulationblanket/intumescent material parts, as shown in FIG. 19, are to beinserted inside of the protective cloth coverings (i.e., shown as atemplate in FIG. 18 b). The T-shaped structure (as is shown in FIG. 18.)is shown again in this figure only as a guide for the placement of theinsulation blanket/intumescent material parts. This step will completethe assembly of the horizontal T-joint/vertical expansion joint fire.

FIG. 19 a is a perspective view of a horizontal T-joint/verticalexpansion joint fire barrier installed in a model horizontalT-joint/vertical expansion joint structure for seaming and for purposesof illustration. In this illustration the intumescent strip layer isabout to be positioned on the insulation blanket side walls. The barrieris shown temporarily attached to the model structure with clamps.

FIG. 20 is a plan view illustrating four schematic multi-dimensionalexpansion joint structures. Of course, it is appreciated that there aremany variation of multi-dimensional expansion joint structures.

FIG. 21 is a perspective view of the novel work form that has beendesigned to hold the barrier that is shaped and sized to fit into a 90degree expansion joint structure for seaming.

FIG. 21 a is another perspective view of the novel work form that isrequired for the seaming of a fire barrier that is shaped and sized tofit into a 90 degree expansion joint structure.

FIG. 22 a is an exploded view to illustrate the various layers that areassembled one over another in a fire resistant layered fire barrier. Thefire resistant barrier illustrated in FIGS. 22 a through 22 f, whenfully assembled, comprises a structure that may be described as having avertical arm that extends at an angle from one of its ends to form ahorizontal arm, which arms provide for the barrier to be installed as aone-piece drop-in unit into an architectural expansion joint spacedefined by the approximately 90° intersection of vertical expansionjoint 80 and horizontal expansion joint 82 (see expansion jointsillustrated in FIGS. 23 d-23 f) referred to a vertical/horizontal joint.It is well known that expansion joints act like chimney flues in thatthey provide channels for fire, smoke, poisonous gases, and heat totravel through to spread the fire throughout a structure. Up until thepresent invention there was no way to stop the spread of the firethrough extension joints that were not simply straight line extensionjoints. The fire resistant fire barriers of the present inventionprovide a solution for this problem in that they provide fire barriersfor joints that are not straight line joints. One such joint is thevertical/horizontal joint. In particular FIG. 22 a illustrates thematerial sheets that may be described as constituting two layers; afirst layer comprises protective support cloth sheet 30 having a firstand a second surface and flanges 32, first insulation blanket sheet 40having a first and a second surface, with the second surface ofprotective cloth 30 positioned under and contiguous to the first surfaceof the first insulation blanket 40, which protective cloth providesprotection and mechanical support for the fire barrier; on the secondsurface of first insulation blanket 40 is arranged intumescent materialsheet 20; first resilient mechanical support sheet 50, here shown as aflexible, resilient screening having a first and second surface, whichfirst surface of resilient screening 50 is arranged over the secondsurface of insulation blanket 40 with its layer of intumescent sheet 20.As shown in more detail in FIG. 4, the stitching that attaches theintumescent material to the blanket goes through the intumescent strips,the blankets, and the protective cloth, so that all of the sheets arebonded together to provide for a unitary, ready-to-use, drop-in unit. Asecond layer comprises second insulation blanket sheet 42 having a firstand second surface and second resilient mechanical support sheet 52having a first and second surface, with the first surface of supportsheet 52 positioned over the second surface of second insulation blanket42.

FIG. 22 b, a perspective view, illustrates the layers, as illustrated inFIG. 22 a, positioned and assembled one over another forming the basicstructure of layered fire barrier 110. Attachment means 76B fixedlyattaches the layers to each other. The sheets comprising each layer arefixedly attached to each other in the same manner, which is illustratedin FIG. 27. The sheets comprising each layer may be fixedly attached toeach other using any known or yet to be known method for affixing suchsheets. The technology of affixing sheets is well known and need not bediscussed further here.

FIG. 23 a, a perspective view, illustrates the structural relationshipsbetween fire barrier 110, as shown in FIG. 22 b, support/attachmentstrips 60, and installation tool 100. Installation tool 100 is uniquelyshaped for installing a 90° vertical/horizontal fire barrier into anexpansion joint space defined by the approximately right-angledintersection of a vertically oriented expansion joint and a horizontallyoriented expansion joint. Installation tool 100 is required for theone-step drop-in placement of the barrier. Having the ability ofinstalling the barrier in a one-step drop-in placement using thespecially made installment tool provides substantial cost savings inthat the barriers are able to be installed easily, rapidly, andcorrectly by a single person with minimal, if any, risk of damage to thebarrier. Non-flammable strapping 60 is shown positioned for attachmentto and through the vertical portion and the horizontal flange portion ofthe barrier and attaches second resilient mechanical support 52, secondinsulation blanket 42, first resilient mechanical support sheet 50,first insulation blanket 40, and protective cloth 30 to each other andprovides for the vertical section of the fire barrier to remain securein a vertical position regardless of any physical stress that may beplaced on the barrier, such as motion the fire barrier may experiencedue to the movement of the building structural units that is facilitatedby the expansion joints. Non-flammable stripping material 60 is a commonand inexpensive metal stripping material, often having apertures alongits length. Positioned over barrier 110, stripping material 60 alsoserves as a means of reversibly attaching installation tool 100 tobarrier 110 using attachment means 76.

FIG. 23 b, a perspective view, illustrates support/attachment strips 60affixed to barrier 110 using pins 72 in conjunction with frictionfitting washer 70T. The reversible attachment of installation tool 100to fire barrier 110 is accomplished in the examples provided usingsupport/attachment strips 60 and a series of pins 72T that projectbeyond the upper surface of the flanges of the layered barrier alongwith friction fitting washers 70T (for more detail see FIG. 27). At thetime of manufacture, pins 72T are inserted completely through the firebarrier from the first surface side of flange 32 of protective cloth 30.Each pin is positioned, relative to the fire barrier, so that pin head73T is situated beneath and up against protective cloth 30 providing forthe length of pin 72T to extend from pin head 73T up through flange 32of protective cloth 30, first non-flammable supporting mesh 50, secondnon-flammable supporting mesh 52, and through non-flammable stripping60. Once all of the pins are in place, friction fitting washers 70T arepositioned over the extending ends of pins 72T and the fire barrier isready to reversibly accept installation tool 100.

FIG. 23 c, a perspective view, illustrates installation tool 100reversibly affixed to fire barrier 110 which is now ready for a one-stepdrop-in installation into an expansion joint. After installation tool100 is positioned on barrier 110 by fitting the apertures of fasteners76T over the extending ends of pins 72T, a spacer 74 is placed overextending ends of pins 72T (spacer 74 is clearly illustrated in FIG.27). The function of the spacer is to provide for easy removal ofinstallation tool 100 from barrier 110 once the installation of barrier110 an expansion joint is complete. Friction fit washers 72T (washers72T are clearly illustrated in FIG. 27) are then positioned about eachpin over each spacer. Installation tool 100 is now firmly, butreversibly, attached to barrier 110. The attachment of the tool onto thebarrier, as described, provides for one person to be able to install thebarrier into a receiving expansion joint. Grasping means, such as handle106 allows one person to lift the barrier, carry it to the place ofinstallation, and lift and drop the barrier into place.

FIG. 23 d, a perspective view, illustrates fire resistant barrier 110installed into the space formed by the intersection of verticalexpansion joint 80 with horizontal expansion joint 82 with installationtool 100 still attached to the barrier. Installation tool 100 will beremoved when barrier 110 is fixedly attached to the building units thatdefine the vertical/horizontal expansion joint. Also pointed out in thefigure are those tool segments 102 that may be removed from tool frame104 and replaced with longer or shorter segments providing for use ofthe installation tool with 4-way fire barriers that occur in a number ofwidths, such as four, six, eight, ten, and twelve inch wide expansionjoints. All of the installation tools, according to the principles ofthe present invention may be adjusted for width in a similar manner.

FIG. 23 e, a perspective view, illustrates fire resistant barrier 110 inthe process of being fixedly attached to building units 90 using pins72T and friction fit washers 70T functionally inserted through aperturesthat are commonly found in stripping 60. It is to be understood that theattachment means used to fixedly attach the barrier to the buildingunits may be any known or yet to be known attachment means, such asbolts, screws, nails, staples, and adhesive to name a few.

FIG. 23 f, a perspective view, illustrates the barrier fixedly attachedto building units 90 by attachment means comprising pins 72T andfriction fit washers 70T securely and tightly positioned to and throughstripping 60 and its installation tool 100 removed. Once the barrier isin place, the installation tool is easily and rapidly removed, ready foruse in emplacing another barrier into another expansion joint. To removethe installation tool from the barrier, a simple leverage type tool,such as a screw driver or a pair of pliers is used to remove each spacer74 and friction-fit washer 70T that had been positioned over the spacer.Once all of the spacers and washers are lifter off of the pins, the toolmay easily be raised and removed from the barrier. At this point, ifdesired, the protruding pins may be simply and rapidly removed bysnipping off their protruding length with a pair of wire snips.Installation tool 100 is easily and rapidly removed by prying up onwashers 72 that were positioned over spacers 74 enabling the easyremoval of both washer and spacer.

The FIGS. 22-23 series illustrate a multi-planar, i.e.,vertical/horizontal layered fire barrier. However, the layered firebarriers according to the principles of the present invention alsoprovide barriers for use in planar angled expansion joints. Threecommonly occurring planar expansion joints are those formed by theplanar approximately right-angled intersection of two, three, and fourexpansion joints resulting in L-shaped, T-shaped, and cross-shapedplanar expansion joints, such as those illustrated schematically in FIG.20.

FIG. 24 a, a perspective view, illustrates 4-way fire barrier 440 thatmay be described to be in the form of a cross, which form fits into thecross-shaped planar space defined by the right-angled intersection offour architectural expansion joints that constitute the space betweenbuilding units 90. The planar cross-shaped fire barrier is constructedin the same double layered manner as the vertical/horizontal firebarrier described above and is attached to building units 90 using thesame attachment means, or similar means that provide for the samefunction, including the use of the non-flammable stripping material, aswas described above for the vertical/horizontal barrier. It is to beappreciated that the angle of intersection of the expansion joints,building units and barrier arms may be any acute, obtuse, or rightangle.

FIG. 24 b, a perspective view, illustrates 4-way fire barrier 440 withits uniquely shaped installation tool 400 firmly attached for one-stepdrop-in installation of planar 4-way fire barrier 440 into a planar4-way planar expansion joint. Installation tool 400 is attached tobarrier 440 in the same manner as was described above for thevertical/horizontal barrier using the same attachment means, or similarmeans that provide for the same function

FIG. 25 a, a perspective view, illustrates T-shaped fire barrier 330,which is simply a 4-way barrier with one arm removed, thus a T-shapedbarrier comprises three arms all in the same horizontal plane forfitting into an expansion joint space defined by the intersection ofthree planar approximately right-angled expansion joints. The layeredT-shaped barrier, as the barriers described above, is constructed of thetwo layers where each layer comprises a resilient mechanical supportsheet over and attached to an insulation blanket having a layer ofintumescent material over the blanket, where one layer is positionedover the other layer to form a layered fire barrier, and where thedouble layer is underlain by a protective cloth having flanges thatcoincide with flanges that extend from the resilient mechanical supportsheet. The layered flanges and the stripping provide attachment meansfor the attachment of an installation tool to its related fire barrierand for the attachment of the fire barrier to the building units 90 aswas described above. Tool 400 has the width adjustable properties thatare available on all of the installation tools of the present invention.

FIG. 25 b, a perspective view, illustrates T-shaped fire barrier 330with its uniquely shaped installation tool 300 firmly attached to thebarrier for one-step drop-in installation of planar T-shaped firebarrier 330 into a three-way planar expansion joint, as described above.The layered flanges and the stripping provide attachment means for theattachment of an installation tool to its related fire barrier and forthe attachment of the fire barrier to the building units 90 as wasdescribed above. Tool 300 has the width adjustable properties that areavailable on all of the installation tools of the present invention. Thewidth adjustments, as described above, are made easily and rapidly usingthe set of width adjusting segments that are provided with each tool.

FIG. 26 a, a perspective view, illustrates two-way or L-shaped firebarrier 220, which is simply a 3-way barrier with one arm removed.Barrier 220 comprises two arms approximately 90° to each other withtheir bases in the same horizontal plane, which barrier fits into atwo-way expansion joint space defined by the approximately right-angledintersection of one expansion joint with a second expansion joint

FIG. 26 b, a perspective view, illustrates two-way or L-shaped firebarrier 220, with its uniquely shaped installation tool 200 firmlyattached to the barrier for one-step drop-in installation of planarT-shaped fire barrier 220 into a two-way right-angled expansion joint.The layered flanges and the stripping of the barrier, as with thebarriers previously described, provide attachment means for theattachment of installation tool 200 to fire barrier 220 and for theattachment of the fire barrier to building units 90, as described above.Tool 200 has the width adjustable properties that are available on allof the installation tools of the present invention. The widthadjustments, as described above, are made easily and rapidly using theset of width adjusting segments that are provided in the tool kit foruse with each tool.

FIG. 27 provides a cross-section view, taken along line FIG. 27-FIG. 27of FIG. 23 d, of the vertical/horizontal fire illustrated in FIG. 23 d,to illustrate one of the many methods and means that is used to attachthe vertically oriented portions of the individual barrier sheets toeach other to form a layer. In this example, pin. 72B is shown extendingthrough the sheets 30, 40, and 50, of a first layer and is also shownbeing held in place by a first friction-fit washer 70B positioned aboutone of its ends and by a second friction-fit washer 70B positioned abouta second end. A second layer, comprising sheets 42 and 52, is formed inan analogous manner, as shown. Additionally, FIG. 27 illustrates one waythat installation tool may be attached to a fire barrier, which in thisillustration is a vertical/horizontal barrier, for installation of thebarrier into an expansion joint. All of the installation tools arereversibly attached to their respective barriers in analogous manners.The means and method illustrated include the use of friction-fit washers70T, spacers 74, and pins 72T with pin heads 73T (see discussion of FIG.23 d for more detail).

FIG. 28, a perspective view, illustrates an example of a kit thatcontains the parts needed to assemble one or all of installation toolsof the present invention, as desired. Kit 500, offering a variety ofstorage compartment 502, may provide all of the basic parts required forthe construction of a desired installation tool and the tools that areused in the tool's construction, such as the set of Allen wrenches 503for assembling and changing width of installation tools, as well as thetools that are used for reversibly attaching and detaching the tool fromits related fire barrier, or optionally, may provide all of the partsand tools needed to assemble the entire suite of the fire barriers ofthe present invention. As illustrated, the kit is a kit of parts thatare commonly referred to as 80/20. This product in a general sense iswell known by those of ordinary skill in the art and does not needfurther discussion here. It is to be understood, however, that theinstallation tools of the present invention may be made any suitablematerial, which can include parts of wood, plastic, and the like. Alsoillustrated in FIG. 28 are installation tool extension parts 505 thatprovide for the tool to be used with fire barriers designed to fit jointspaces of varying widths. The installation tools according to theprinciples of the present invention are unique to this invention. Theyare made to be used solely with the fire barriers of the presentinvention and because each tool is shaped to fit with a particularlyshaped fire barrier, the tools cannot be used for any other functionwith any other device. Each particular style of fire barrier has amating installation tool. As the tools are reusable, providing for onlyone tool per style of fire barrier being required. For example, if aninstaller is ready to install a plurality of the vertical/horizontalfire barriers, the installer starts the installation process by simplyplacing the installation tool over the surface of the fire barrier forthe tool and firmly attaching the tool to the barrier. Because dynamicexpansion joints occur in a variety of widths, the most common beingfour, six, eight, ten, and twelve inches, each of the installation toolscomprises a basic frame with width determining exchangeable installationtool segments 504. Each installation tool is supplied with a set 505 ofwidth determining exchangeable installation tool segments providing foreach tool to be used in any of the basic joint widths by making an easyand rapid switch of width determining exchangeable installation toolsegments.

Thus, it can be seen from the above that the present invention providesthe solution to the long felt and extremely important safety need formeans to prevent the rapid spread of flames, heat, and smoke throughoutmulti-dimensional expansion joints of any type of structure by providingfire barriers styled and sized to fit multi-dimensional expansionjoints, as well as the method of making the barriers, and the forms onwhich the barriers are seamed. Moreover, as the multi-dimensional firebarriers of the present invention may be constructed of presentedavailable and permitted materials, the added cost to manufacture thebarrier is minimal, thus making these essential safety features,affordable.

The foregoing description, for purposes of explanation, used specificand defined nomenclature to provide a thorough understanding of theinvention. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice theinvention. The disclosed descriptions and illustrations are not intendedto be exhaustive or to limit the invention to the precise formsdisclosed. Those skilled in the art will recognize that many changes maybe made to the features, embodiments, and methods of making the versionsof the invention described herein without departing from the spirit andscope of the invention, such as adjusting the template patterns shown inthe drawings and described above to fit the variety of other similar,but different, multi-dimensional expansion joints, as well as to fit thevarious sizes of multi-dimensional joints that require fire barriers.Furthermore, the present invention is not limited to the describedmethods, embodiments, features or combinations of features but includeall the variation, methods, modifications, and combinations of featureswithin the scope of the appended claims. The invention is limited onlyby the claims.

1. Fire resistant barriers for installation into fire, heat, and smokefunneling flue-like spaces formed by the angled intersection of at leasttwo architectural expansion joints, comprising: fire barriers comprisinga plurality of fire resistant material layers including: a first layercomprising: a fire resistant protective cloth sheet having a first andsecond surface, and a first fire resistant insulation blanket sheethaving a first and second surface, said second surface of saidprotective cloth sheet positioned under and contiguous to said firstsurface of said first insulation blanket sheet providing protection andmechanical support for the fire barrier; at least one layer of a firstfire resistant intumescent material sheet arranged on said secondsurface of said first insulation blanket sheet; a first fire resistantresilient mechanical support sheet having a first and second surface,said first surface of said first resilient mechanical support sheetpositioned over said second surface of said first insulation blankethaving a layer of said intumescent sheet, and a second layer comprising:a second fire resistant insulation blanket sheet having a first andsecond surface, and a second fire resistant resilient mechanical supportsheet having a first and second surface, said first surface of saidsecond resilient mechanical support sheet positioned over said secondsurface of said second insulation blanket; said second layer positionedover said first layer so that said first surface of said secondinsulation blanket is positioned over said second surface of said firstresilient mechanical support sheet, said layers locally bonded togetherforming a unitary layered fire barrier ready for installation withinsaid expansion joints spaces, and mounting means for fixedly mountingsaid barrier to building structural units defining said expansion jointsproviding for a barrier against the travel of fire, heat, or smokethrough flue-like channels created by the expansion joints of astructure.
 2. The fire barriers, as recited in claim 1, wherein saidprotective cloth further includes mounting means for affixing saidlayered fire barrier to said building structural units.
 3. The firebarriers, as recited in claim 2, wherein said mounting means furthercomprise mounting flanges comprising the side edge portions of theprotective cloth.
 4. The fire barriers, as recited in claim 2, whereinsaid mounting means further comprise a plurality of fasteners used inconjunction with said flanges providing for said fire barrier to beaffixed to said building structural units.
 5. The fire barriers, asrecited in claim 4, further comprising wherein said plurality offasteners further comprises a plurality of pins and washers used inconjunction with said flanges providing for said fire barrier to beaffixed to said building structural units.
 6. The fire barriers, asrecited in claim 1, wherein said mounting means further comprises atleast one reusable mounting tool for depositing said fire barrier withinsaid expansion joints for affixation to said building structural units;said at least one reusable mounting tool comprising: a sturdy framereversibly attachable to said fire barrier using reversible attachmentmeans, and at least one grasping means on said frame, said graspingmeans providing for easy lifting and positioning of the frame and thereversibly attached fire barrier into said expansion joints.
 7. The firebarriers, as recited in claim 6, further comprising wherein said frameof said mounting tool is width adjustable to accommodate the varyingwidths of the fire barriers.
 8. The fire barriers, as recited in claim6, further comprising wherein said at least one reusable mounting toolfurther comprises a kit of mounting tools for installation of said firebarriers into the spaces formed by the angled intersection ofarchitectural expansion joints.
 9. The fire barriers, as recited inclaim 1, further comprising wherein said fire resistant barrier iscontoured in the form of a cross for fitting into a planar intersectionof four architectural expansion joints.
 10. The fire barriers, asrecited in claim 1, further comprising wherein said fire resistantbarrier is contoured to form a T-shape for fitting into a planarapproximately right-angled intersection of three architectural expansionjoints architectural expansion joints.
 11. The fire barriers, as recitedin claim 1, further comprising wherein said fire resistant barrier iscontoured to form an L-shape for fitting into a planar approximatelyright-angled intersection of two architectural expansion joints.
 12. Thefire barriers, as recited in claim 1, further comprising wherein saidfire resistant barrier is contoured to form an L-shape for fitting intoa non-planar approximately right-angled intersection of twoarchitectural expansion joints.
 13. The fire barriers, as recited inclaim 1, wherein said non-planar approximately right-angled intersectionof two architectural expansion joints further comprises an intersectionof a vertically oriented expansion joint with a horizontally orientedexpansion joint.
 14. A method for installing fire resistant barriersinto fire, heat, and smoke funneling flue-like spaces formed by theangled intersections of at least two architectural expansion joints,comprising the steps of: providing for fire barriers comprising aplurality of fire resistant material layers including: a first layercomprising: a fire resistant protective cloth sheet having a first andsecond surface, and a first fire resistant insulation blanket sheethaving a first and second surface, said second surface of saidprotective cloth sheet positioned under and contiguous to said firstsurface of said first insulation blanket sheet providing protection andmechanical support for the fire barrier; at least one layer of a firstfire resistant intumescent material sheet arranged on said secondsurface of said first insulation blanket sheet; a first fire resistantresilient mechanical support sheet having a first and second surface,said first surface of said first resilient mechanical support sheetpositioned over said second surface of said first insulation blankethaving a layer of said intumescent sheet, and a second layer comprising:a second fire resistant insulation blanket sheet having a first andsecond surface, and a second fire resistant resilient mechanical supportsheet having a first and second surface, said first surface of saidsecond resilient mechanical support sheet positioned over said secondsurface of said second insulation blanket; positioning said second layerover said first layer so that said first surface of said secondinsulation blanket is positioned over said second surface of said firstresilient mechanical support sheet, bonding said layers locally togetherforming a unitary layered fire barrier ready for installation withinsaid expansion joints spaces, and fixedly mounting said barrier usingmounting means to building structural units defining said expansionjoints providing a barrier against the travel of fire, heat, or smokethrough flue-like channels created by the expansion joints of astructure.
 15. The method, as recited in claim 14, further comprisingwherein said fire resistant barrier is contoured in the form of a crossfor fitting into a planar intersection of four architectural expansionjoints.
 16. The method, as recited in claim 14, further comprisingwherein said fire resistant barrier is contoured to form a T-shape forfitting into a planar approximately right-angled intersection of threearchitectural expansion joints architectural expansion joints.
 17. Themethod, as recited in claim 14, further comprising wherein said fireresistant barrier is contoured to form an L-shape for fitting into aplanar approximately right-angled intersection of two architecturalexpansion joints.
 18. The method, as recited in claim 14, furthercomprising wherein said fire resistant barrier is contoured to form anL-shape for fitting into a non-planar approximately right-angledintersection of two architectural expansion joints.
 19. The firebarriers, as recited in claim 14, wherein said non-planar approximatelyright-angled intersection of two architectural expansion joints furthercomprises an intersection of a vertically oriented expansion joint witha horizontally oriented expansion joint.
 20. Fire barriers forinstallation into fire, heat, and smoke funneling spaces formed by theapproximately right-angled intersections of at least two architecturalexpansion joints, comprising: fire resistant barriers comprising aplurality of fire resistant material layers including: at least one fireresistant insulation blanket sheet having a first and a second surface;at least one layer of fire resistant intumescent material sheet; atleast one fire resistant resilient mechanical support sheet having afirst and a second surface; said at least one layer of said intumescentmaterial is disposed between said second surface of said at least oneinsulation blanket sheet and said first surface of at least oneresilient mechanical support sheet, at least one fire resistantprotective cloth sheet positioned beneath and contiguous to said firstsurface of said at least one insulation blanket sheet, said protectivecloth providing protection and mechanical support, said at least oneprotective cloth sheet, said at least one insulation blanket sheet, saidat least one layer of intumescent material sheet, and said at least oneresilient mechanical support sheet are locally bonded together forming alayered fire barrier ready for installation within said spaces formed bysaid expansion joints intersecting at angles therein providing a barrieragainst the travel of fire, heat, or smoke through the flue-likechannels created by the expansion joints of a structure.